My 89 tracker has an annoying exhaust leak which I think I have tracked down to the exhaust manifold.  I replaced the exhaust from the the cat back about three months ago along with the O2 sensor.  Af first it was leaking at the manifold/exhaust pipe coupler but fixed that too.  It's only under acceleration and more noticeable when the motor is cold.  I am thinking it's between the head and the exhaust manifold.  Should I get a new one or just have the flanges milled flat and put a new gasket?  Labor is cheap here in Costa Rica.....I would really prefer a new header but shipping one here is expensive.  Anyone have any experience with this problem?  BTW the motor is the 1.6 8v with TBI injection.

Check and make sure there isn't a crack, I have seen a few with a crack between the number 3 and 4 cylinder on the manifold.

Will do......I have been reading this is a common problem on these motors and can lead the engine running rich if not fixed.  Thanks!

Did you find anything?

Sure did   Small crack right around the O2 sensor which I had just replaced a couple of months ago.  The leak is more noticeable when the engine is cold and less noticeable when warm.  It's not very large and my idle seems to be rock solid at 850 rpm, so I don't think it's sucking too much air around the sensor.  I'd like to replace the whole thing with a header but they are just too expensive down here.  I'm looking into a replacement here at the local parts store.  Thanks for the tip!

You can find people who can weld cast, it just usually doesn't last very long.